Board removal method for a pallet

ABSTRACT

A board removal apparatus for a wooden pallet includes a frame, and a carriage carried by the frame. The carriage includes a pair of spaced apart tables with a fixed gap therebetween. The carriage is movable between a pallet receiving position and a board removal position. The pallet is positioned on the carriage when in the pallet receiving position so that a board to be removed overlies the fixed gap. A board removal assembly is carried by the frame and includes a push rod and a board removal foot pad pivotally coupled thereto. The push rod and the board removal foot pad are inserted between adjacent stringers on the pallet when the carriage is in the board removal position.

RELATED APPLICATION

This is a divisional patent application of U.S. patent application Ser.No. 12/019,815 filed Jan. 26, 2008 now U.S. Pat. No. 8,266,790 B2, theentire disclosure of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to pallet inspection and repair systems,and more particularly, to a pallet repair apparatus.

BACKGROUND OF THE INVENTION

Wooden pallets are used to transport a variety of bulk goods andequipment as required in manufacturing and warehousing operations. Inhigh volume industries, pallet pools provide a lower total industry costthan one-way pallets. The current assignee of the present inventionrecognizes the benefits of pooled pallets, and currently has overseveral hundred million pallets that are pooled each year.

After the bulk goods and equipment are off loaded from the pooledpallets, the pallets are returned to pallet inspection and repairfacilities for inspection, and if necessary, repair, before the palletsare returned to service.

As one might expect, wooden pallets are subject to damage in use thatoccurs from handling with forklifts or other like equipment. Sincewooden pallets are in wide use, a large number of damaged and unusablepallets need to be repaired or discarded daily during the palletinspection and repair process. Repair of damaged pallets has become anincreasingly sound alternative to disposal due to the sheer volume ofpallets that require repair each day.

Pallet inspection and repair traditionally requires manual handling andinspection by an operator, with mechanized systems available for movingpallets to and from the human operator who completes the repair of thepallets. An automated pallet inspection and repair system isadvantageous because it does not rely on a human operator to perform theinspection and repair.

U.S. published patent application no. 2006/0242820 discloses anautomated pallet inspection and repair system, which is assigned to thecurrent assignee of the present invention and is incorporated herein byreference in its entirety. The automated pallet inspection and repairsystem discloses an automatic pallet inspection cell comprisingmulti-axis robot arms that terminate in either internal or exteriorpallet grippers. A robot may be used to transport a gripped palletthrough an automated pallet inspection station that generates athree-dimensional data map of a pallet surface. A processor interpretsthe map and generates a corresponding repair recipe.

One or more repair stations may conduct pallet repair operations thatare specified by the repair recipe. For removing damaged or brokenboards on the pallet, the '820 published patent application discloses aboard removal machine comprising a stationary horizontal band saw. Thepallet is positioned in such a way that the blade of the band saw islocated between adjacent boards of the pallet. By linearly advancing thepallet toward the blade, the nails or other fasteners used to hold aboard can be cut so that the board can be completely removed. Whileeffective in removing boards from the pallet, there is a need to improvesuch a process.

SUMMARY OF THE INVENTION

In view of the foregoing background, it is therefore an object of thepresent invention to provide a board removal apparatus to be used inremoving damaged boards from a pallet.

This and other objects, advantages and features in accordance with thepresent invention are provided by a board removal apparatus for a woodenpallet comprising a frame, and a carriage carried by the frame. Thecarriage may comprise a pair of spaced apart tables with a fixed gaptherebetween, and may be movable between a pallet receiving position anda board removal position. The wooden pallet is positioned on thecarriage when in the pallet receiving position so that a board to beremoved overlies the fixed gap. The wooden pallet typically comprises aplurality of spaced apart stringers, and a plurality of boards on topand bottom surfaces thereof.

At least one board removal assembly may be carried by the frame and maycomprise at least one push rod and at least one board removal foot padpivotally coupled thereto. The at least one push rod and the at leastone board removal foot pad may be inserted between adjacent stringerswhen the carriage is in the board removal position. The at least oneboard removal foot pad may overlie at least a portion of the board to beremoved, and may also overlie at least a portion of the fixed gapbetween the pair of spaced apart tables.

The board removal apparatus may further comprise an upper support armpad and a lower support arm. The upper support arm pad may be coupled tothe frame for resisting an upward force of the wooden pallet when the atleast one board removal foot pad applies a board removal force forremoving the board. The lower support arm pad may be pivotally coupledto the frame to provide a counter force on the board to be removed asthe at least one board removal foot pad applies the board removal force.The counter force is less than the board removal force for maintainingthe board in a substantially horizontal position during removal thereoffrom the wooden pallet.

The board removal apparatus advantageously removes damaged boards from apallet in an efficient and safe manner. This helps to increaseproductivity in repairing damaged pallets, as well as improving workersafety since a band saw or a crowbar type lever is not used by theworker to remove the damaged boards.

The at least one board removal assembly may further comprise at leastone transfer plate pivotally coupled between the at least one boardremoval foot pad and the at least one push rod for transferring theboard removal force to the at least one board removal foot pad. The atleast one push rod may comprise a pair of push rods coupled to atransfer plate. The transfer plate preferably pivots the board removalfoot pad to within the fixed gap between the pair of spaced aparttables. This allows the removed board to be easily discarded away fromthe pallet.

The at least one board removal assembly may further comprise at leastone push rod link coupled to the at least one push rod, and at least oneactuator coupled to the at least one push rod link for generating theboard removal force. The at least one board removal assembly has afloating end and a fixed end coupled to the frame, with the floating endincluding the at least one board removal foot pad.

The at least one board removal assembly may further comprise a pair ofspaced apart board removal assemblies, with each board removal assemblyinserted between different adjacent stringers when the carriage is inthe board removal position. The carriage may further comprise at leastone pallet clamping mechanism carried by each table.

The lower support arm pad may be inserted in the fixed gap between thepair of spaced apart tables for contacting the board to be removed whenthe carriage is in the board removal position. At least one lowersupport arm actuator may be coupled between the frame and the lowersupport arm pad for providing the counter-force. After the board hasbeen removed from the wooden pallet, the at least one lower support armpad actuator may move the lower support arm pad within a range of about30 to 60 degrees for discarding the removed board.

Another aspect of the present invention is directed to a method forremoving a board from a pallet using a board removal apparatus asdefined above. The method may comprise positioning the pallet on thecarriage in the pallet receiving position so that the board to beremoved overlies the fixed gap between the pair of spaced apart tables.The carriage may be moved to the board removal position, with the atleast one push rod and the at least one board removal foot pad beinginserted between adjacent stringers. The at least one board removal footpad may overlie at least a portion of the board to be removed, and mayalso overlie at least a portion of the fixed gap between the pair ofspaced apart tables. The at least one push rod may be moved fortransferring a board removal force to the at least one board removalfoot pad for removing the board from the pallet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top-level block diagram of a pallet inspection and repairsystem in accordance with the present invention.

FIG. 2 illustrates a forklift removing pallets from a truck prior toinspection in accordance with the present invention.

FIG. 3 is a schematic diagram of the stack in-feed illustrated in FIG.1.

FIG. 4 is a schematic diagram of the tipper/accumulator illustrated inFIG. 1.

FIG. 5 is a schematic diagram of a preparation screening line forreceiving pallets from the tipper/accumulator illustrated in FIG. 4.

FIGS. 6 and 7 are schematic diagrams of the automated digital inspection(ADI) station illustrated in FIG. 1.

FIGS. 8 and 9 respectively illustrate a pallet repair summary table andan element repair summary table generated by the ADI station inaccordance with the present invention.

FIGS. 10, 11 and 12 respectively illustrate different configurations ofthe top deck boards of a pallet as well as element ID and indexing ofthe boards in accordance with the present invention.

FIG. 13 illustrates the bottom deck baseboards of a pallet as well aselement ID and indexing of the boards in accordance with the presentinvention.

FIG. 14 illustrates the stringers of a pallet as well as element ID andindexing of the boards in accordance with the present invention.

FIG. 15 is a schematic diagram of the classification divert lineillustrated in FIG. 1.

FIG. 16 is a more detailed block diagram of the different repairmachines/repair devices associated with the repair line illustrated inFIG. 1.

FIG. 17 is a side view of a board removal apparatus with a pallet in thepallet receiving position in accordance with the present invention.

FIG. 18 is a side view of the board removal apparatus illustrated inFIG. 17 with the pallet in the board removal position.

FIG. 19 is a top view of the board removal apparatus illustrated in FIG.17.

FIG. 20 is a more detailed top view of one of the board removalassemblies illustrated in FIG. 19.

FIG. 21 is a side view of the board removal assembly illustrated in FIG.20 with the board removal foot pad in an extended position.

FIG. 22 is a more detailed rear view of one of the board removalassemblies illustrated in FIG. 19.

FIG. 23 is a flow diagram for removing a board from a pallet using aboard removal apparatus in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Likenumbers refer to like elements throughout.

A top-level overview of the pallet inspection and repair system 40 willinitially be discussed with reference to FIG. 1. Pooled pallets 50 fromdifferent customers are returned to a pallet pooling company forinspection, and if necessary, repair, before the pallets are returned toservice 51. As the pallets 50 are received, customer data is collectedand recorded. Customer data includes the customer providing the pallets,along with how many pallets are being returned. Customer data may alsoinclude other pertinent information about the customer, as readilyappreciated by those skilled in the art.

Prior to inspection, the pallets 50 are provided to a stack in-feed 52.As the pallets 50 are placed in the stack in-feed 52, customer data 70associated with the pallets are provided to at least one processor,referred to herein as a factory management system (FMS) server 56. Aseach pallet 50 is individually tracked through the pallet inspection andrepair system 40 by an automated controller 60, the FMS server 56 keepstrack of the corresponding customer data 70 to be associated therewith.

The stack in-feed 52 squares each stack of pallets before being passedto a tipper/accumulator 62. The tipper/accumulator 62 provides a steadystream of spaced apart pallets 50 for inspection by the automateddigital inspection (ADI) station 66. As the pallets 50 leave thetipper/accumulator 62, they pass through a preparation screening line64.

In the preparation screening line 64, each pallet 50 is visuallyinspected by a human operator to remove any loose debris or trash thatmay affect the ADI station 66. If necessary, the human operator willalso make minor repairs. Each pallet 50 is individually tracked throughthe preparation screening line 64 by the automated controller 60. Insome cases, a pallet 50 may be discarded during the preparationscreening line 64 if it is damaged too badly, as indicated by block 65.

From the preparation screening line 64, each pallet 50 is inspected bythe ADI station 66. The ADI station 66 may be configured as one or twoinspection booths. As part of the inspection, image data 72 is generatedfor the pallet 50. The ADI station 66 compares the generated image data72 to an expected profile 74. The generated image data 72 may also bereferred to as measurement data, and the expected profile 74 may also bereferred to as pallet classification. Based on the comparison, a damagereport 76 is generated. As will be discussed in greater detail below,the damage report 76 comprises a pallet repair summary and an elementrepair summary.

The damage report 76 is sent to the FMS server 56. The FMS server 56generates a repair recipe 78 for the inspected pallet 50 based on thedamage report 76. During the pallet inspection and repair process, theinformation in the FMS server 56 (i.e., repair recipes 78) is queried.The inspected pallet 50 travels from the ADI station 66 to aclassification divert line 68.

The classification divert line 68 may also be referred to as a sortline, and queries the FMS server 56 to determine if the inspected palletis good or bad. If the inspected pallet 50 is bad, this means that thepallet requires repair (via repair line 80) or is to be discarded (viadiscard line 84). If the inspected pallet 50 is good, then the pallet 50is sent to the paint booth 82 prior to being returned to service 51.

Prior to being sent to the repair line 80, the classification divertline 68 may position which way the pallets are to face for the repairsto be made. The repair line 80 includes a series of processor-controlledrepair machines/repair devices available for repairing each pallet 50based on the corresponding repair recipe 78, as will be discussed ingreater detail below. Depending on how extensive the pallet 50 isdamaged, the number of repair machines/repair devices involved in therepair can vary from one to more than one. In addition, certain repairsmay be manually made by a human, as readily appreciated by those skilledin the art.

As illustrated in FIG. 1, the automated controller 60 controls thetipper/accumulator 62, the preparation screening line 64, the ADIstation 66 and the classification divert line 68. In this portion of thepallet inspection and repair system 40, the pallets 50 are moved on aconveyor system, for example. A series of detectors, such as photocells,for example, are positioned along the conveyor system for trackingposition and movement of each pallet. The automated controller 60 is acomputer-based controller that tracks the position and movement of eachpallet 50 via the sensors, and coordinates with the ADI system 66 onwhen the image data 72 of each pallet 50 is to be generated.

For each pallet 50, the corresponding customer data 70 and repair recipe78 are provided from the FMS server 56 to another processor, which isreferred to herein a data analysis server 58. The data analysis server58 is illustrated as being separate from the FMS server 56.Alternatively, the FMS server 56 and the data analysis server 58 couldbe configured as a single server or processing system, as readilyappreciated by those skilled in the art.

The data analysis server 58 performs post-analysis processing for theinspected pallets 50. This involves comparing the repair recipes 78 todetermine performance repair parameters 90 for the pallets 50. Theperformance repair parameters 90 correspond to the different types ofrepairs to be made to the pallets.

As a result of analyzing the types of repairs being made to the pallets50, statistical data can be collected including how many pallets arebeing repaired, how much time and lumber is being consumed or isexpected to be consumed in repairing the pallets, as well as trackingwhat repairs are being made. This advantageously allows the throughputof the pallet inspection and repair system 40 to be monitored so thatlumber and personnel can be accurately forecasted.

By determining certain repair trends, changes may be made to the palletinspection and repair system 40 to more efficiently make the repairs.This may involve modifying one or more of the processor-controlledrepair devices, or even the addition of a processor-controlled repairdevice if the repair was initially being manually made by a humanoperator.

Moreover, the repair trends may cause an examination of the inspectiontolerances associated with the ADI station 66, for example. If one ormore of the inspection tolerances are set to stringent, this may causeunnecessary repairs to be made to the pallets 50. By relaxing theinspection tolerances, less repairs would be made with the pallets 50still meeting customer demands.

The performance repair parameters 90 may also be tracked with thecustomer data so that feedback can advantageously be provided to thecustomer. The feedback would allow corrective action to be taken by thecustomer to reduce certain types of repairs being made to the palletsprovided by that customer.

By analyzing the types of repairs being made to the pallets for aparticular customer, certain trends may be noted. For example, thecustomer may be damaging the supports blocks on the pallets more oftenthan other customers, or the top deck boards are being replaced moreoften than other customers. Corrective action may be for the customer toinstruct their forklift operators to reduce impacting the forklift tineswith the support blocks, and to not stack loaded pallets too high on topof one another, for example. If the customer ignores the feedback, thenthe customer may be charged a higher rate on their pooled pallets.

The pallet inspection and repair system 40 will now be discussed ingreater detail. Referring now to FIG. 2, a forklift 100 is used tounload wooden pallets 50 from a tractor-trailer truck 102. A standardtractor-trailer truck 102 holds about 500 pallets 50, for example. Asthe pallets 50 are unloaded, a vehicle mount terminal (VMT) 104 on theforklift 100 records the customer data 70. The customer data 70 includesthe truck number, the customer providing the pallets 50, and how manypallets are being unloaded for inspection. The customer data 70 isentered into the VMT 104 by the operator of the forklift 100. Thisprocess is repeated each time pallets 50 are unloaded from a truck 102or any other delivery vehicle.

At the stack in-feed 52, the forklift 100 places the wooden pallets 50against a backboard 124, as illustrated in FIG. 3. As the pallets 50 arestacked, the VMT 104 communicates with the FMS server 56. The FMS server56 may also be referred to as a logistics database, for example.

The stack in-feed 52 comprises a series of conveyors 110, 112, 114 and116, which are controlled by electrical motors 119. The illustratedarrow 107 indicates the flow direction of the pallets 50. Each conveyorhas one or more detectors 120 for determining the position of a stack ofpallets 122 as it moves along the conveyors 110, 112, 114 and 116. Thedetectors 120 may be photoelectric sensors, or photoeyes, for example. Aphotoelectric sensor is used to detect the presence of a stack ofpallets 122 by using a light transmitter, often infrared, and aphotoelectric receiver. Other types and forms of detectors 120 may beused, as readily appreciated by those skilled in the art.

The pallets 50 are initially stacked on a conveyor 110 against thebackboard 124 to form a stack of pallets 122. Each illustrated stack ofpallets 122 is 20 pallets high. After a stack of pallets 122 has beenformed, the stack moves from conveyor 110 to a stack squarer 126 viaconveyor 112. The stack squarer 126 squares each stack of pallets 122.After being squared, the conveyor 114 associated with the stack squarer126 moves the stack of pallets 122 to an adjacent conveyor 116. Thisconveyor 116 then moves the stack of pallets 122 toward thetipper/accumulator 62.

The tipper/accumulator 62 comprises a tipper 130 and an accumulator 140,as the name implies, as illustrated in FIG. 4. The illustrated arrow 107indicates the flow direction of the pallets 50. The tipper 130 includesan L-shaped member that is tilted from a first position in which thelong side 132 of the L-shaped member is upright and the short side 134is horizontal, to a second position in which the long side 132 is nearhorizontal and the short side 134 is near vertical (as in FIG. 4). Whenthe short side 134 of the L-shaped member is in the horizontal position,the stack of pallets 122 is loaded onto the tipper 140. After loading,the tipper 140 moves the L-shaped member to the second position in whichthe long side 132 of the tipper is nearly horizontally disposed so thatthe pallets 50 held on the L-shaped member can be moved off the tipper130 to the accumulator 140.

The accumulator 140 provides an intermediate stage between the stack ofpallets 122 and the preparation screening line 64. The tipper 130delivers and transfers the stack of pallets 122 to the accumulator 140which then holds and delivers the pallets 50 one at a time to thepreparation screening line 64. This is while the tipper 130 returns toreceive another stack of pallets 122.

At the output of the accumulator 140, the pallets 50 are passed toanother series of conveyors 150, 152, 154, 156, 158 and 160 defining thepreparation screening line 64, as illustrated in FIG. 5. The illustratedpreparation screening line 64 is one example, and others variations arereadily applicable. The illustrated arrow 107 indicates the flowdirection of the pallets 50. Detectors 120 are spaced along theconveyors 150-160 for tracking the position of each pallet 50. Thepallets 50 from the accumulator 140 are placed with the top deck facingup on conveyor 150. The top deck of each pallet 50 is visually inspectedby a human operator to insure that any loose debris or trash is removedfrom the pallet 50 before reaching the ADI station 66. Also, any looseboards on the top deck that can be easily repaired may also be naileddown at this time. If the human operator determines that the pallet 50is too damaged to be repaired, then the pallet is discarded at thispoint.

The pallets 50 travel along conveyor 152 and are then flipped because ofthe transition with conveyor 154 so that the bottom deck is now facingup. Likewise, the bottom deck of each pallet 50 is visually inspected bya human operator to insure that any loose debris or trash is removedfrom the pallets before reaching the ADI station 66. As with the topdeck, any loose boards on the bottom deck that can be easily repairedmay also be nailed down at this time. Again, if the human operatordetermines that the pallet 50 is too damaged to be repaired, then thepallet is discarded at this point.

The pallets 50 travel along conveyor 156 and are then flipped over atconveyor 158 so that the top deck is again facing up. This is so the ADIstation 66 first inspects the top deck of each pallet 50. The pallets 50continue moving on conveyor 160 toward the ADI station 66.

The next step in the pallet inspection and repair system 40 is toinspect the pallets 50, as illustrated in FIGS. 6 and 7. The illustratedembodiment for the ADI station 66 shown in FIG. 1 comprises a pair ofADI inspection stations 180, 182. The illustrated arrow 107 indicatesthe flow direction of the pallets 50.

During the inspection process, the top and bottom decks of each pallet50 are inspected in separate ADI inspection stations 180, 182. Conveyor170 receives a pallet 50 from conveyor 160 in the preparation screeningline 64. The top deck of the pallet 50 is inspected in ADI inspectionstation 180. Detectors 120 are used to track movement of the pallet 50prior to entering the ADI station 180, as well as tracking movementwithin the ADI station.

The ADI station 180 inspects the top deck of the pallet 50 using palletfeature sensing heads 190 placed above the pallet. Each pallet featuresensing head 190 may comprise a series of sensors in a line (lineararray) to detect the presence or absence of timber (or other palletmaterial), as discussed in the above-referenced patent application thatis incorporated herein by reference. This type of sensing head ispositioned adjacent to the moving pallet 50 so that it scans the palletsurface passing near it for generating an image 72 of the pallet.

In another embodiment, the pallet feature sensing head 190 may comprisea laser and camera system to capture individual profiles(cross-sections) of the pallet 50 (i.e., the camera records the locationof a projected laser line and triangulates its position to give heightand coordinate data). The laser beam that is projected onto the pallet50 may be fan shaped, or it may be scanned across the pallet surfaceusing, for example, moving mirrors. Such a system will generate athree-dimensional digital data map on the pallet 50 and can be used fordetecting gaps or protrusions such as nails, hanging wood, etc.

Alternatively, similar three-dimensional maps of pallet features,dimensions and topography may be created using a system of cameras,which may be stereoscopic or monocular in location and action. These canbe mathematically manipulated to give data on each element that can thenbe analyzed for damage as in other pallet feature sensing headarrangements.

The ADI station 180 has at least one computing system 194 cooperatingwith the pallet feature sensing heads 190 for generating an image of thetop deck of the pallet 50 being inspected. Likewise, the other ADIstation 182 has at least one computing system 194 cooperating with thepallet feature sensing heads 190 for generating an image of the bottomdeck of the pallet 50.

Between the ADI stations 180 and 182, conveyor 172 moves the pallet 50to conveyor 174, wherein the transition between the two conveyors causesthe pallet to flip over so that the bottom deck is facing up. The pallet50 then moves on conveyors 176 and 178 to the ADI station 182 forinspecting the upper facing bottom deck.

Although not illustrated, the two computing systems 194 and 204 arecoupled together for generating a damage report 76 on the pallet 50. Thecomputing system 194 compares the generated image data 72 for the topand bottom decks of the pallet 50 with expected profiles 74 forgenerating the damage report 76.

The damage report 76 comprises a pallet repair summary and an elementrepair summary. The pallet repair summary and the element repair summarymay be configured as tables, as illustrated in FIGS. 8 and 9. Theelement repair summary corresponds to the elements making up the pallet50. For example, the top deck of the pallet 50 could be formed with 5, 6or 7 boards as illustrated in FIGS. 10, 11 and 12. Accordingly, when apallet 50 is to be inspected, the pallet needs to be classified as a 5,6 or 7 board pallet. The corresponding element ID 206 and element index208 for each type of pallet are also provided.

Once the pallet 50 has been classified, then the expected profile can beselected by the computing systems 194, 204. Similarly, the elementsmaking up the bottom deck of the pallet 50, and the elements making upthe stringer boards of the pallets are illustrated in FIGS. 13 and 14.The corresponding element ID 206 and element index 208 for the palletare also provided.

As an alternative to separate ADI stations 180 and 182, a single ADIstation may be used when pallet feature sensing heads 190 are positionedbelow the conveyor. In this embodiment, the pallet 50 does not have tobe flipped over so that the bottom deck is facing up during inspection.In addition, a single computing system 194 may be used.

As illustrated in FIG. 1, the damage report is provided to the FMSserver 56. Since the damage report 76 includes the pallet repair summarytable and the element repair summary table as illustrated in FIGS. 8 and9, the FMS server 56 generates a repair recipe 78 for the pallet 50.

The repair recipe 78 determines how the pallet 50 is to be repaired ifit is damaged. The repair recipe 78 takes into account the inspectionresults, the complexity of the repair and the repair machines availableand the paths available (with respect to the repair machines) in thepallet inspection and repair system 40. The repair recipe 78 also takesinto consideration what repair operations get priority if multiplerepairs have to be made to the pallet 50. The FMS server 56 thus createsa relational database scheme for handling the very large number ofrepair variables that are possible when repairing pallets 50.

Conveyor 180 moves the pallet 50 from the second ADI station 182 to theclassification divert line 68, as illustrated in FIG. 15. Theclassification divert line 68 includes a conveyor 185 for receiving thepallet 50 from the second ADI station 182. Conveyor 210 operates as acontrol gate for directing the pallet 50 to conveyor 212 or to conveyor208. Conveyor 212 provides the pallet 50 to conveyor 214 which directsthe pallet to the repair line 80. Conveyor 208 provides the pallet 50 tothe paint booth 82. Although not illustrated, the classification divertline 68 also directs the pallet to the discard line 84 if the pallet 50is too damaged to be repaired. The classification divert line 68 thusoperates based on the repair recipe 78.

In the repair line 80, a number of different processor-controlled repairdevices and repair machines are available to support a complete repairof a pallet 50. The repair line 80 includes the following: a de-stubbingdevice 240, a lead board adjustment apparatus or machine 242, a nailingmachine 244 for the lead board adjustment machine, an any board removalapparatus or machine 246, a board placing/nailing machine 248, a leadboard removal machine 250 and a nail presser for proud nails 252. Inaddition, some repairs may be manually made by a human, either directlyor with the human operating a repair machine, as indicated by reference254. The order in which a pallet 50 is repaired in the repair line 80 isbased on the generated repair recipe 78.

The repair recipe 78 may be provided to the repair line 80 in a numberof different ways. For example, the position of each pallet 50 is stillbeing tracked so that the repair recipe 78 “travels” with each pallet.Alternatively, each pallet 50 may be physically marked with their repairrecipe 78 before leaving the classification divert line 68. This may bein the form of a bar code, or as a set of written instructions. Once thepallet 50 arrives at the repair line 80, the repair recipe 78 is read.The repair recipe 78 may be read by a processor or by a human operator.

As part of the repair line 80, one or more robot cells may be used toposition each pallet 50 among the different repair devices/machinesbased on the repair recipe 78. Alternatively, conveyors with switchgates may be used for providing the pallets 50 to the appropriate repairdevices/machines based on the repair recipe 78.

After a pallet 50 has been repaired, or for a pallet that did not needrepair, the pallet may be sent to the paint booth 82 before beingreturned to service. In one embodiment, several pallets 50 are placed inthe paint booth 82 at one time. The paint booth 82 is enclosed, and thepallets 50 spin as edges or sides of the pallets are sprayed with paint.Next, a stencil may be used to mark the pallets with indicia, such asthe company logo. In one embodiment, a robot is used for dipping itspaint guns into a pit of paint for marking at least two pallets at atime. An alternative design is to use an inkjet type paint sprayer tospray in a dot matrix format the indicia.

In the discard line 84, the pallets 50 are dismantled. A robot, forexample, may be programmed to dismantle the pallets 50.

Another aspect of the pallet inspection and repair system 40 is directedto the board removal apparatus or machine 246, which is used to removedamaged boards from a pallet 50. The board removal apparatus 246 mayalso be referred to as an any board removal apparatus.

Referring now to FIGS. 17, 18 and 19, the illustrated board removalapparatus 246 comprises a frame 400, and a carriage 402 carried by theframe. The carriage 402 comprises a pair of spaced apart tables 404 witha fixed gap 406 therebetween. The carriage 402 is movable between apallet receiving position (FIGS. 17 and 19) and a board removal position(FIG. 18). The pallet 50 is positioned on the carriage 402 in the palletreceiving position so that a board 51 to be removed overlies the fixedgap 406. The width of the fixed gap 406 is greater than the width of theboard 51 to be removed. In the illustrated embodiment, a chain drive 410is used to move the carriage 402 under the control of an electricalmotor 412 from the pallet receiving position to the board removalposition. A chain to carriage attachment point is indicated by reference413. Rollers 415 are carried by each table 404 for assisting withmovement of the pallet 50 thereon.

Each table 404 has a clamping mechanism 408 associated therewith forsecuring the pallet 50 to the carriage 402. The clamping mechanisms 408clamp along the outer edges of the pallet 50. Depending the placement ofthe pallet 50 on the carriage, the clamping mechanism 408 on one of thetables is sufficient for securing the pallet 50. The clamping mechanisms408 may be pneumatically operated, as will be readily understood bythose skilled in the art. However, other types of clamping mechanismsare acceptable for securing the pallet 50 to each table 404.

In the illustrated embodiment, a pair of board removal pad assemblies420 is carried by the frame 400. Each board removal pad assembly 420comprises at least one push rod 428 and at least one board removal footpad 422 pivotally coupled thereto. In the illustrated embodiment, a pairof push rods 428 is pivotally coupled to a board removal foot pad 422.For each board removal pad assembly 420, the corresponding pair of pushrods 428 and the board removal foot pad 422 are inserted betweenadjacent stringers when the carriage 402 is in the board removalposition. The board removal foot pad 402 overlies at least a portion ofthe board 51 to be removed, and also overlies at least a portion of thefixed gap 406 between the pair of spaced apart tables 404. The removalpads 422 thus extend parallel to the fixed gap 406.

An upper support arm pad 430 is coupled to the frame 400 for resistingan upward force of the pallet 50 when the board removal foot pad 402applies a board removal force for removing the board 51. The illustratedupper support arm pad 430 is pivotally coupled to the frame 400, and islocked into position prior to the board removal force being applied bythe board removal foot pad 402. As a design alternative, the uppersupport arm pad 430 would be unnecessary if the frame 400 was strongenough to withstand the board removal force, i.e., a board lever force,generated by the board removal pad assemblies 420. The illustrated uppersupport arm pad 430 overlies the board removal foot pads 422. The uppersupport arm pad 430 is coupled to a pair of transfer links 433 and 435for moving the upper support arm pad 430 up and down. An upper supportarm actuator 437 for controlling movement of the upper support arm pad422 is coupled between the frame 400 and one of the transfer links 435.The upper support arm actuator 437 locks the upper support arm pad 430into position prior to the board removal force being applied by theboard removal foot pad 402. The upper support arm actuator 437 may behydraulically controlled, for example.

A lower support arm pad 432 is pivotally coupled to the frame 400 toprovide a counter force on the board 51 to be removed as the boardremoval foot pads 422 apply a board removal force for removing theboard. The counter force is less than the board removal force formaintaining the board 51 in a substantially horizontal position duringremoval thereof from the pallet 50. The lower support arm pad 432 iscarried by an arm 443 that is pivotally coupled to the frame 400. Alower support arm actuator 447 for controlling the lower support arm pad432 is coupled between the frame 400 and the arm 443. The lower supportarm actuator 447 may be hydraulically controlled, for example.

The board removal pad assemblies 420 will now be discussed in greaterdetail with reference to FIGS. 20, 21 and 22. Each board removal padassembly 420 further comprises a push rod link pivotally coupled betweenan actuator 424 and the push rods 428. The push rod link includes acentral arm 426 coupled to a shaft 429. The shaft 429 extends outwardtoward a pair of outer push rod arms 451. As the actuator 424 pushes onthe central arm 426, the outer pair of push rod arms 451 transfers aboard removal force to the respective push rods 428.

The push rods 428 in turn transfer the board removal force to the boardremoval foot pad 422 via a transfer plate 453. As the board 51 isremoved, the transfer plate 453 pivots the board removal foot pad 422and board to within the fixed gap 406 between the pair of spaced aparttables 404. Connection pins 455 are used to couple the push rods 428 tothe transfer plate 453. Pivot pins through the support plate 453 causeit to rotate downwards when the board removal force is applied to thepush rods 428.

Operation of the board removal apparatus 246 is based on a controller330, which includes a hydraulics controller section 332 and a pneumaticscontroller section 334. For purposes of simplifying the drawings,interfaces between the controller sections 332, 334 and thecorresponding hydraulic and pneumatic actuators 424, 437 and 447 are notshown, but will be readily understood by those skilled in the art.

The controller 330 may operate based on a processor for controlling thehydraulics controller section 332 and the pneumatics controller section334. The controller 330 also controls movement of the carriage 402. Thecontroller 330 operates in response to the repair recipe 78 generated bythe FMS server 56 for the pallet 50. Alternatively, the controller 330may be operated independently from the repair recipe 78 for removing aboard 51 from the pallet 50, as will be appreciated by those skilled inthe art.

Each board removal assembly 420 has a floating end 500, and a fixed end502. The fixed end 502 is coupled to the frame 400 at connection points504. The floating end 500 is tapered so that it can more easily beinserted between adjacent stringers on the pallet 50. As the free end500 of the board removal foot pads 422 apply the board removal force forremoving the board 51, the upper surface of the fixed end 502 contactsand pushes upwards on the inside of the pallet 50.

As noted above, the lower support arm pad 432 is pivotally coupled tothe frame 400 to provide a counter force on the board 51 to be removedas the board removal foot pads 422 apply the board removal force forremoving the board. The lower support arm actuator 447 moves the lowersupport arm pad 432 within a range of about 30 to 60 degrees from thecarriage 402 when the board 51 has been removed. This allows the removedboard 51 to be readily discarded.

After the board 51 has been removed, the upper support arm 430 isunlocked and retracted, and the carriage 402 moves back to the palletreceiving position. The pallet clamps 408 are unclamped and the pallet50 is removed or repositioned for removal of another board.

A method for removing a board 51 from a pallet 50 using a board removalapparatus 246 is also provided. The board removal apparatus 246comprises a frame 400, and a carriage 402 carried by the frame andcomprising a pair of spaced apart tables 404 with a fixed gap 406therebetween. The carriage 402 is movable between a pallet receivingposition and a board removal position. At least one board removal padassembly 420 is carried by the frame 400 and includes at least one boardremoval pad 422 overlying at least a portion of the fixed gap 406 whenthe carriage 402 is in the board removal position.

Referring now to FIG. 23, from the start (Block 600), the methodcomprises positioning the pallet 50 on the carriage 402 in the palletreceiving position so that the board 51 to be removed overlies the fixedgap 406 between the pair of spaced apart tables 404 at Block 602. Thecarriage is moved to the board removal position at Block 604. In thisposition, the at least one push rod 428 and the at least one boardremoval foot pad 422 are inserted between adjacent stringers. The atleast one board removal foot pad 422 overlies at least a portion of theboard 51 to be removed, and also overlies at least a portion of thefixed gap 406 between the pair of spaced apart tables 404. The at leastone push rod 428 is moved at Block 606 for transferring a board removalforce to the at least one board removal foot pad 422 for removing theboard 51 from the pallet 50. The method ends at Block 608.

In the illustrated board removal apparatus 246, the carriage 402 ismoved with the pallet 50 thereon with respect to the stationary pair ofboard removal pad assemblies 420. Alternatively, the carriage 402 withthe pallet 50 thereon may be stationary and the pair of board removalpad assemblies 420 is movable with respect to the carriage, as will bereadily appreciated by those skilled in the art.

Many modifications and other embodiments of the invention will come tothe mind of one skilled in the art having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is understood that the invention is not to be limited tothe specific embodiments disclosed, and that modifications andembodiments are intended to be included as readily appreciated by thoseskilled in the art.

That which is claimed:
 1. A method for removing a board from a palletusing a board removal apparatus comprising a frame, a carriage carriedby the frame and comprising a pair of spaced apart tables with a fixedgap therebetween, the carriage being movable between a pallet receivingposition and a board removal position, the pallet comprising a pluralityof spaced apart stringers and a plurality of boards on top and bottomsurfaces thereof, and at least one board removal assembly carried by theframe and comprising at least one push rod and at least one boardremoval foot pad pivotally coupled thereto, the method comprising:positioning the pallet on the carriage in the pallet receiving positionso that the board to be removed overlies the fixed gap between the pairof spaced apart tables; moving the carriage to the board removalposition, with the at least one push rod and the at least one boardremoval foot pad being inserted between adjacent stringers, and with theat least one board removal foot pad overlying at least a portion of theboard to be removed and overlying at least a portion of the fixed gapbetween the pair of spaced apart tables; and moving the at least onepush rod for transferring a board removal force to the at least oneboard removal foot pad for removing the board from the pallet.
 2. Themethod according to claim 1 wherein the board removal apparatus furthercomprises an upper support arm pad coupled to the frame for resisting anupward force of the wooden pallet when the at least one board removalfoot pad applies the board removal force for removing the board.
 3. Themethod according to claim 1 wherein the board removal apparatus furthercomprises a lower support arm pad pivotally coupled to the frame toprovide a counter force on the board to be removed as the at least oneboard removal foot pad applies a board removal force for removing theboard, with the counter force being less than the board removal force.4. The method according to claim 3 wherein the counter force is formaintaining the board in a substantially horizontal position duringremoval thereof from the pallet, and after the board has been removedfrom the pallet, the at least one lower support arm pad moves within arange of about 30 to 60 degrees for discarding the removed board.
 5. Themethod according to claim 1 wherein the at least one board removalassembly further comprises at least one transfer plate pivotally coupledbetween the at least one board removal foot pad and the at least onepush rod for transferring the board removal force to the at least oneboard removal foot pad, with the at least one transfer plate pivotingthe at least one board removal foot pad to within the fixed gap betweenthe pair of spaced apart tables.
 6. The method according to claim 5wherein the at least one push rod comprises a pair of push rods coupledto the at least one transfer plate.
 7. The method according to claim 1wherein the at least one board removal assembly has a floating end and afixed end coupled to the frame, with the floating end including the atleast one board removal foot pad.
 8. The method according to claim 1wherein the at least one board removal assembly comprises a pair ofspaced apart board removal assemblies, with each board removal assemblyinserted between different adjacent stringers when the carriage is inthe board removal position.
 9. The method according to claim 1 whereinthe lower support arm pad is inserted in the fixed gap between the pairof spaced apart tables for contacting the board to be removed when thecarriage is in the board removal position.
 10. A method for removing aboard from a pallet using a board removal apparatus comprising a frame,a carriage carried by the frame and comprising a pair of spaced aparttables with a fixed gap therebetween, the carriage being movable betweena pallet receiving position and a board removal position, the palletcomprising a plurality of spaced apart stringers and a plurality ofboards on top and bottom surfaces thereof, and at least one boardremoval assembly carried by the frame and comprising at least one pushrod and at least one board removal foot pad coupled thereto, the methodcomprising: positioning the pallet on the carriage in the palletreceiving position so that the board to be removed overlies the fixedgap between the pair of spaced apart tables; moving the carriage to theboard removal position, with the at least one push rod and the at leastone board removal foot pad being inserted between adjacent stringers;and moving the at least one push rod for transferring a board removalforce to the at least one board removal foot pad for removing the boardfrom the pallet.
 11. The method according to claim 10 wherein the boardremoval apparatus further comprises an upper support arm pad coupled tothe frame for resisting an upward force of the wooden pallet when the atleast one board removal foot pad applies the board removal force forremoving the board.
 12. The method according to claim 10 wherein theboard removal apparatus further comprises a lower support arm padcoupled to the frame to provide a counter force on the board to beremoved as the at least one board removal foot pad applies a boardremoval force for removing the board, with the counter force being lessthan the board removal force.
 13. The method according to claim 10wherein the counter force is for maintaining the board in asubstantially horizontal position during removal thereof from thepallet, and after the board has been removed from the pallet, the atleast one lower support arm pad moves within a range of about 30 to 60degrees for discarding the removed board.
 14. The method according toclaim 10 wherein the at least one board removal assembly furthercomprises at least one transfer plate coupled between the at least oneboard removal foot pad and the at least one push rod for transferringthe board removal force to the at least one board removal foot pad, withthe at least one transfer plate moving the at least one board removalfoot pad to within the fixed gap between the pair of spaced aparttables.
 15. The method according to claim 14 wherein the at least onepush rod comprises a pair of push rods coupled to the at least onetransfer plate.
 16. The method according to claim 10 wherein the atleast one board removal assembly has a floating end and a fixed endcoupled to the frame, with the floating end including the at least oneboard removal foot pad.
 17. The method according to claim 10 wherein theat least one board removal assembly comprises a pair of spaced apartboard removal assemblies, with each board removal assembly insertedbetween different adjacent stringers when the carriage is in the boardremoval position.
 18. The method according to claim 10 wherein the lowersupport arm pad is inserted in the fixed gap between the pair of spacedapart tables for contacting the board to be removed when the carriage isin the board removal position.